Dairy Processor
Climeaction Case Studies
Overview
A leading independent dairy processor, set out to achieve Net Zero (Scope 1 & 2) emissions by 2030. Like many in the dairy sector, this comopany faced challenges balancing business growth with decarbonisation targets while maintaining production efficiency and quality.
The Challenge
Achieving meaningful, long-term decarbonisation required a clear, data-driven roadmap grounded in detailed audits, operational analysis, and strategic investment planning. This leading dairy processor partnered with Climeaction to develop a phased pathway to Net Zero (Scope 1 & 2) by 2030, covering multiple high-energy processes including pasteurisation, drying, refrigeration, water treatment, and CIP systems.
The site faced several challenges: high thermal energy demand driven by steam and hot water requirements; ageing utility infrastructure with limited integration; operational inefficiencies caused by outdated controls and variable scheduling; and the need for a phased approach to capital investment.
Like many processors, the company required a practical roadmap that delivered immediate energy and carbon savings while embedding operational excellence and continuous improvement to support long-term, sustainable transformation.
The Solutions
Climeaction developed a phased decarbonisation roadmap that combined low-cost optimisation with targeted capital investments to maximise impact, efficiency, and financial return.
Phase 1 (Year 1) – Operational Excellence & Quick Wins
Focused on rapid operational improvements, including BMS and control upgrades, nitric acid recovery, full steam system optimisation (leak and trap surveys with repairs), boiler burner and O₂ control upgrades, and compressed air system enhancements. Additional measures included TOC meter installation, EEOS funding support, and assistance with Origin Green certification.
Phase 2 (Year 2) – Process Optimisation & Efficiency Enhancements
Delivered deeper utility and process optimisation, including redesigned CIP recipes, improved CHW sequencing and temperature control, elimination of non-productive dryer run time, economiser retrofits with enhanced condensate recovery, and HP/LP steam system balancing with insulation upgrades.
Phase 3 (Year 3) – Reliability & System Upgrades
Prioritised system reliability through boiler descaling, improved feedwater treatment, high-efficiency ammonia compressor upgrades with VSDs, and water-reduction initiatives supported by expanded metering and process-water reuse opportunities.
Phases 4–5 (2025–2030) – Decarbonisation Systems & Renewable Integration
The final phases will embed international standards (ISO 50001, ISO 46001, and ISO 14001) while deploying renewable and recovery technologies, including CIP heat and water recovery, industrial heat pumps for low-grade heat recovery and steam displacement, large-scale solar PV, and expanded digital metering to enable continuous, data-driven performance management.
Our Results - Dairy Processor
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